Die-cushion: Controlled counterpressure for demanding forming tasks
A die-cushion provides what many spring systems fail to deliver. It generates controlled counterpressure throughout the entire forming process. Integrated directly into the press, it replaces classic springs in the tool and delivers consistent performance. The force curve remains stable, regardless of the installation space, tool design, or cycle time. For anyone who cannot accept fluctuations in the deep drawing process, the Die-cushion is the right solution.
When the press cycle does not allow for deviations
Tools with individual springs do not deliver uniform force application. Even the smallest differences between the springs lead to deviations in the forming process. The result is tears, wrinkles, or shape defects. With high cycle rates and large series, each of these defects is costly.
The die-cushion works independently of the tool. It is permanently installed in the press and replaces mechanical or compressed air spring components with an adjustable force unit. The resistance built up by the cushion remains virtually constant throughout the entire process, even with temperature differences, material fluctuations, or long running times.
The moving masses are about 100 times lower with nitrogen die-cushion than with compressed air die-cushion for the same forces and stroke lengths. This protects your press and your tools. Problem tools can suddenly be operated at significantly higher stroke rates and without tool damage.
Structure and function of a Die-cushion
Typical sequence:
- Before the stroke, the die-cushion is preloaded and ready to apply force
- As the tool moves down, the die-cushion generates the defined counterpressure
- The counterpressure remains almost constant throughout the entire stroke.
- After the drawing process, the cushion returns to its starting position in a controlled manner.
Depending on the design, pressure, speed, force profile, and retraction can be precisely adjusted to the manufacturing process. Modern die-cushions can be controlled fully automatically via the press control system.
Where Die-cushion demonstrate their technical strengths
Die-cushion are used where spring systems reach their design or functional limits. They enable precisely controlled force application during deep drawing, improve repeat accuracy, and significantly reduce wear on the tool.
- Deep drawing tools with high force requirements and limited installation space
- Workpieces made of high-strength steel, aluminum, or other challenging materials
- Applications with freely definable cushion stroke and adjustable force
- Press lines with automated parts handling and continuous operation
- Series production with high cycle rates and tight dimensional tolerances
- Production environments with limited maintenance capacity and long downtimes
In these cases, the Die-cushion contributes significantly to stable processes, longer tool life, and economical production.
N2-Tech delivers more than just a Die-cushion
Unlike springs, there is no standard path for die-cushion. Each system is individually designed for your press, your tool, and your component geometry. N2-Tech handles this design process entirely in-house.
Our services at a glance:
- Analysis of the forming task and force curves
- Design and layout of the die-cushion according to installation space and cycle time
- Possible controlled return stroke functions
- Design of guide and support elements
- Coordination with press control
- Delivery, documentation, installation, and commissioning
- Assistance with testing prior to commissioning
- Training and long-term system support
Technical advantages of the N2-Tech die-cushion solution
Precisely defined cushion stroke
Controlled return stroke speed
Significant reduction in tool load
Longer service life thanks to machine-bound system
Reproducible processes in any environmental situation
Whether daily fluctuations, material tolerances, or temperature differences: Die-cushion works independently of these factors with constant pressure and consistent performance.